Training Factory Industry 4.0 9V: Digitized learning and simulation model for industry 4.0 applications

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fischertechnik, Fabrik 4.0, 13.03.19 in Waldachtal. Foto: Jakob Studnar

Art.-No. 551584_simLink to the eLearning portal with in-depth technical informationAdvantages:

Training and simulation on a realistic production model as well as in-depth learning through haptic comprehension
Optical and sensory applications and Digital traceability with NFC/RFID
Integrated cloud connection, control via smart devices as well as using and operating dashboards
Web-based remote maintenance as well as linking of production and materials planning data
Connection of upstream and downstream logistics processes

Product Description

The fischertechnik learning environment is used for learning and understanding industry 4.0 applications in vocational schools and training as well as for research, teaching and development at universities, in companies and IT departments. The simulation depicts the ordering process, the production process and the delivery process in digitised and networked process steps.

Factory environment

This consists of the factory modules like storage and retrieval stations, vacuum suction pads, high-bay warehouse, multi-processing station with kiln, a sorting section with colour detection, an environmental sensor and a pivoting camera. After the order has been placed in the dashboard, the workpieces pass through the respective factory modules and the current status is immediately visible on the dashboard.The integrated environmental sensor reports values for temperature, humidity, air pressure and air quality. The camera sees the entire system through the vertical and horizontal pan range and can thus be used for web-based remote maintenance.Individual workpieces are tracked using NFC (Near Field Communication): A unique identification number (ID) is assigned to each workpiece. This enables traceability and visibility of the current status of the workpieces in the machining process.

Control

The learning factory 4.0 is controlled by the 9V-based fischertechnik TXT controller; its six units are installed. These are networked within the factory and communicate with each other via MQTT. MQTT (Message Queuing Telemetry Transport) is an open message protocol that enables the transmission of data in the form of messages between devices. The complete performance data of the TXT controller can be viewed at www.fischertechnik.de/simulate; the most important features are:

Dual processor: ARM Cortex A8 (32-bit/600MHz) + Cortex M3
Storage capacity: 256 MB DDR3 RAM, 128 MB Flash
Storage extension: Micro SD card slot
Display: colour 2.4” touch display (320×240 pixels)
8 universal inputs: Digital/analogue 0-9VDC, analogue 0-5 kΩ
4 quick counter inputs: Digital, frequency up to 1 kHz
4 motor outputs 9 V/250 mA (maximum: 800 mA): Infinitely variable speed, short-circuit-proof, alternatively 8 individual outputs, e.g. for lamps
Combined Bluetooth/WiFi wireless module: BT 2.1 EDR+ 4.0, WiFi 802.11 b/g/n
Infrared receiver diode
USB 2.0 client: Mini USB port for connection with the PC
USB Host port: USB-A port for fischertechnik USB camera, USB sticks, etc .
Camera interface: via USB host, Linux camera drivers integrated in the operating system
10-pole pin row to increase inputs and outputs as well as I2C-port
Integrated loudspeaker
Integrated real-time clock with replaceable buffer battery for recording the measured values in a defined period
Linux based Open-Source operating system
Programming possible with ROBO Pro, C-Compiler, PC-Library, etc .
Power supply: 9V DC 3.45 mm port, or fischertechnik 2.5 mm ports

Software: C/C++ API programming interface

The software application is written in C/C++ and is loaded on the controller in the ready-to-start status. The corresponding C/C++ library and the API are published on Github: https://github.com/fischertechnik.

This library can be used to write customised C/C++ programs for the learning factory.

fischertechnik cloud

The connection to the fischertechnik cloud is established via the WiFi router supplied and integrated into the learning factory. We recommend using the web browsers such as Chrome or Firefox. The cloud can be used via a personal access that is created once (www.fischertechnik-cloud.com). The cloud servers are located in Germany and ensure that strict European requirements regarding the storage of data are applicable. Personal data is protected in an account with password access that uses extremely secure “OAuth2” industry standard. All data sent to the cloud is transmitted encrypted with certificates (https standard, green lock in web browser).

Dashboard

The dashboard can be accessed and operated via mobile devices such as tablets and smartphones as well as laptops and PCs. It enables platforms to be displayed from three different perspectives:

Customer view
Supplier view
Production view

The customer view shows a webshop interface with a shopping cart, where you can order a workpiece and track the current status of the order in the shopping cart. This process is displayed on the interface for the customer so that he/she is informed about the status of his/her order.

The process of ordering the raw material is displayed and visualised in the supplier view.

The factory status, the production process, the stock, the NFC/RFID reader and the sensor values can be queried in the production view. In addition, the camera that monitors the production line can also be controlled here. All these functions are controlled within a window and actuated via the menu.

In Factory status, the status of the respective module is visualised via a traffic light display. If a fault occurs in production, it is acknowledged via a button after the cause has been rectified and production is continued.The individual manufacturing steps are visually simplified using connected nodes and represented in the Production process view. The currently active node (= production module) lights up green or red when the respective process step is being processed live or there is an error and is waiting to be corrected.

The Inventory production view visualises the current inventory of workpieces including minimum and maximum stock. A reorder point procedure is stored. This production view is used exclusively for visualisation.The production view of the NFC/RFID reader displays the workpiece data and can be used to read or delete workpieces manually. The raw data of the NFC tags can be read using a standard NFC app from mobile devices with NFC readers. Each workpiece has its own unique ID and displays the following data: Status, colour and timestamp from delivery to dispatch.The camera is also controlled via the production view and the read values of the environment sensor can also be viewed here.